ck30 WM 02 engine01-28...0.039 in. Item Factory Specification Allowable Limit f. Rocker Arm 13.973 ~ 13.984 mm 0.55012 ~ 0.55055 in. 13.998 ~ 14.023 mm 0.55110 ~ 0.55209 in.--Item

CHAPTER 2

ENGINE SYSTEM

ENGINE SYSTEM

2-3D704-W00 Dec. 2004

1. FEATURE

704W201A

The TD1300 and 3A150 engines are vertical, water-cooled, 4-cycle, three or four cylinders diesel engines. Theyconcentrate DAEDONG’s foremost technologies.

With swirl combustion chamber, bosch K type fuel injection pump, well-balanced designs, they feature greater power,low fuel consumption, less vibration and noise, and low emission.

CHAPTER 2 CK25(H)/30(H)

2-4 D704-W00 Dec. 2004

704W217A

The lubricating oil is forced to each journal through theoil passages of the cylinder block, cylinder head andshafts. The oil, splashed by the crankshaft or thrown offfrom the bearings, lubricates other engine parts suchas the push rods (11), tappets (12), camshaft (14), andcrankshaft (15).

(1) Piston (5) Strainer (9) Rocker Arm Shaft (13) Oil Pressure Switch

(2) Idle Gear (6) Oil Filter Element (10) Rocker Arm (14) Camshaft

(3) Oil Pump (7) Bypass Valve (11) Push Rod (15) Crankshaft

(4) Relief Valve (8) Oil Pan (12) Tappet

2. LUBRICATING SYSTEM

ENGINE SYSTEM

2-5D704-W00 Dec. 2004

704W221A

The cooling system consists of a radiator (5), a cen-trifugal water pump (7), a cooling fan (6) and a thermo-stat (2). The water is cooled as it flows through the ra-diator core, and the fan behind the radiator pulls thecooling air through the radiator core. The water pumpreceives water from the radiator or from the cylinderhead and forces it into cylinder block. The thermostatopen or closes according to the water temperature.

(1) Water Return Pipe

(2) Thermostat

(3) Cylinder Head Water Jacket

(4) Cylinder Block Water Jacket

3. COOLING SYSTEM

(5) Radiator

(6) Cooling Fan

(7) Water Pump

When the water temperature is high, the thermostatopens to allow the water to flow from the cylinder blockto the radiator. When the water temperature is low, thethermostat closes and the flow stays within the block.The opening temperature of the thermostat is approx.71 °C (160 °F).


2-6 D704-W00 Dec. 2004

704W226A

(1) Fuel Tank (5) Injection Nozzle

(2) Fuel Filter (6) Fuel Overflow Pipe

(3) Injection Pump (7) Fuel Feed Pump

(4) Injection Pipe

The fuel is fed from the fuel tank (1) through the fuelfeed pump (7), through the fuel filter, and then to theinjection pump (3). The injection pump force-feeds thefuel to the injection nozzles (5), which inject the fuelinto the cylinders for combustion. The excess fuel fromthe injection pump and the injection nozzles (5), is col-lected in the fuel overflow pipes (6) and returns to thefuel tank.

4. FUEL SYSTEM

ENGINE SYSTEM

2-7D704-W00 Dec. 2004

5. TROUBLESHOOTING

ENGINE DOES NOT START.

Crankshaft and camshaft have seized up.

Piston and cylinder liner have seized up.

Bearings are oil-stuck.

Lubrication system not working property.

Starter faulty.

Battery capacity is low or terminal loose.

Fuel pipe broken.

Air enters fuel pipe through connection.

Fuel filter clogged.

Fuel pump faulty.

Plunger has worn or seized up.

Delivery valve spring broken.

Delivery valve not completely oil-tight.

Needle valve stuck.

Needle spring broken.

Injection pressure maladjusted.

Injection pipe mounting nut loose.

Injection mistimed. Injection timing maladjusted.

Contact between intake/exhaust valve andseat not tight.

Intake/exhaust valve spring broken.

Intake/exhaust valve stuck.

Gasket faulty.

Tightness torque of cylinder head notenough.

Piston ring stuck.

Piston ring worn.

Cylinder liner worn.

Tightness torque of injection nozzle andglow plug not enough.

Valve clearance excessive.

Crankshaftdoes not turn

Frictional resis-tance of movingparts is too much

Fuel supply toinjection pump isinsufficient.

Injection pumpdoes not send onfuel.

Fuel does notinject throughinjection nozzle.

No or smallfuel injectionsounds.

Compressed airleaks.

Valve actiontiming improper.

Crankshaftturns

Regular fuelinjectionsounds.


2-8 D704-W00 Dec. 2004

Engine does not turn normally.

Engine output insufficient.

Governor spring deformed.

Valve clearance incorrect.

Idling regulator maladjusted.

Accelerator rod maladjusted.

Fuel filter clogged.

Fuel pipes broken or loose.

Air in pump.

Pump capacity not constant.

Tappet roller and pin worn.

Delivery valve not completely oil-tight.

Fuel leaks from nozzle tip.

Fuel not spraying properly.

Injection pump or nozzle not functioningnormally.

Compression pressure is different amongcylinders.

Governor sleeve not sliding property.

Fork lever not functioning normally.

Start spring deformed.

Control rack not sliding property.

Main moving parts have almost seized up.

Engine overheated.

Injection mistimed.

Governor not functioning normally.

Air leaking.

Air cleaner clogged.

Filter clogged.

Fuel pipe broken or loose.

Injection pump’s capacity not enough.

Nozzle needle valve worn.

Governor notfunctioningnormally.

IrregularRevolution

Revolution isnot smooth athigh speeds.

Injectionpump wrong.

Injectionnozzle faulty.

Idlingmaladjusted.

Idling notsmooth.

Compressionpressure notenough.

Fuel supplyinsufficient.

Slow enginerevolutions.

ENGINE SYSTEM

2-9D704-W00 Dec. 2004

Color of exhaust fumes not normal.

Needle valve stuck.

Nozzle spring broken.

Too much carbon sticks to nozzle tip.

Injection pressure too low.

Piston ring stuck.

Piston ring worn.

Excessive gap between cylinder liner andpiston.

Too much oil.

Injection delayed.

Compression pressure insufficient.

Injection too early.

Injection delayed.

Plunger does not return completelybecause spring is stuck or broken.

Plunger worn.

Compressed air leaks.

Not enough air.

Excessive lubricant consumption.

Excessive gap between piston and liner.

Piston ring stuck.

Piston ring worn.

Excessive gap between intake/exhaustvalve and valve stem.

Valve stem seal broken.

Oil leaks from defective packings.

Lubricant increasing.

Injection pump plunger leaks much fuel.

Fuel pump leaks much fuel.

Head gasket packing faulty.

Crankcase cracked.

Hydraulic pump’s oil seal broken.

White or blueexhaustfumes.

Injectionmistimed.

Lubricantrises throughpiston gap.

Black or darkgray exhaustfumes.

Fuel pump’sinjectingcapacity varies.

Nozzle doesnot inject fuelproperly.

Fuel mixedwith oil.

Water mixedwith oil.

Gear oil mixedwith oil.


2-10 D704-W00 Dec. 2004

Valve Clearance (Cold) IN.

EX.

Valve Seat Angle IN.

EX.

Valve Face Angle IN.

EX.

Valve Recessing

Clearance Between Valve Stem and Valve

Guide

Valve Stem O.D

Valve Stem I.D

TD1300A. ENGINE BODYa. Cylinder Head

0.7 ~ 0.9 mm0.0276 ~ 0.0354 in.

When tightened1.18 ~ 1.28 mm

0.0465 ~ 0.0504 in.

3.24 ~ 3.73 MPa

33 ~ 38 kgf/cm2

469 ~ 540 psi

0.05 mm / 100 mm

0.002 in. / 3.94 in.

-

-

2.55 MPa

26 kgf/cm2

370 psi

Item Factory Specification Allowable Limit

Cylinder Head Surface Flatness

Top Clearance

Thickness of gasketFree

Compression Pressure(When cranking with starting motor)

* Variance of compression pressure among cylinders should be 10% or less.

b. Valves

0.1 mm 0.0039 in.

0.1 mm 0.0039 in.

0.785 rad. 45°

0.785 rad. 45°

0.785 rad. 45°

0.785 rad. 45°

1.1 ~ 1.3 mm

0.0433 ~ 0.0512 in.

0.025 ~ 0.055 mm

0.0010 ~ 0.0022 in.

7.960 ~ 7.975 mm

0.31339 ~ 0.31398 in.

8.0 ~ 8.015 mm

0.31496 ~ 0.31555 in.

1.6 mm

0.0630 in.

0.10 mm

0.004 in.

-

-


c. Valve Timing

0.349rad 20° before T.D.C

0.785rad 45° after B.D.C

0.873rad 50° before B.D.C

0.262rad 15° after T.D.C


Inlet Valve Open

Close

Exhaust Valve Open

Close

-

-

6. SERVICING SPECIFICATIONS

ENGINE SYSTEM

2-11D704-W00 Dec. 2004

d. Cylinder Bore

Cylinder bore innerdiameter

82.000 ~ 82.022 mm

3.2283 ~ 3.2292 in.

0.15 mm

0.0059 in.

e. Valve Spring

41.7 ~ 42.2 mm

1.6417 ~ 1.6614 in.

12.0 kgf / 35.15 mm

26.5 lbs / 1.3839 in.

-

41.2 mm

1.6220 in.

10.2 kgf / 35.15 mm

22.5 lbs / 1.3839 in.

1.0 mm

0.039 in.


f. Rocker Arm

13.973 ~ 13.984 mm

0.55012 ~ 0.55055 in.

13.998 ~ 14.023 mm

0.55110 ~ 0.55209 in.

-

-


Rocker arm shaft O.D

Rocker arm bushing I.D

g. Tappet

0.020 ~ 0.062 mm

0.00079 ~ 0.00244 in.

23.959 ~ 23.980 mm

0.94327 ~ 0.94410 in.

24.000 ~ 24.021 mm

0.94488 ~ 0.94571 in.

0.07 mm

0.0028 in.

-

-


Clearance between tappet and guide

Tappet O.D

Tappet guide I.D

h. Camshaft

0.01 mm

0.0004 in.

33.5 ~ 33.6 mm

1.319 ~ 1.323 in.

33.5 ~ 33.6 mm

1.319 ~ 1.323 in.

0.050 ~ 0.091 mm

0.00197 ~ 0.00358 in.

39.934 ~ 39.950 mm

1.57221 ~ 1.57284 in.

40.000 ~ 40.025 mm

1.57480 ~ 1.57579 in.

0.05 mm

0.0020 in.

33.45 mm

1.3169 in.

33.45 mm

1.3169 in.

0.15 mm

0.0059 in.

39.88 mm

1.5701 in.

-


Camshaft alignment

Cam height IN.

EX.

Clearance between camshaft

Camshaft journal O.D

Camshaft counter bore I.D

Free length

Assembling load / assembling length

Squareness



2-12 D704-W00 Dec. 2004

I. Timing Gear

0.04 ~ 0.11 mm

0.0016 ~ 0.0043 in.

0.20 ~ 0.51 mm

0.0079 ~ 0.0201 in.

0.020 ~ 0.054 mm

0.00079 ~ 0.00213 in.

27.967 ~ 27.980 mm

1.10106 ~ 1.10157 in.

28.000 ~ 28.021 mm

1.10236 ~ 1.10319 in.

0.15 mm

0.0059 in.

0.9 mm

0.035 in.

0.1 mm

0.0039 in.

-

-


Timing gear backlash

Idle gear side clearance

Clearance between Idle gear shaft and idlegear bushing

Idle gear shaft O.D

Idle gear bushing I.D

j. Piston Ring

23.00 ~ 23.013 mm

0.90551 ~ 0.90602 in.

0.020 ~ 0.060 mm

0.00079 ~ 0.00236 in.

5.01 ~ 5.03 mm

0.19724 ~ 0.19803 in.

4.97 ~ 4.99 mm

0.19567 ~ 0.19646 in.

0.065 ~ 0.100 mm

0.00256 ~ 0.00394 in.

2.055 ~ 2.070 mm

0.08091 ~ 0.08150 in.

1.97 ~ 1.99 mm

0.07756 ~ 0.07834 in.

0.25 ~ 0.40 mm

0.0098 ~ 0.01570 in.

0.25 ~ 0.40 mm

0.0098 ~ 0.01570 in.

23.053 mm

0.9076 in.

0.15 mm

0.0059 in.

-

-

0.15 mm

0.0059 in.

-

-

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.


Piston pin-bore I.D

Clearance between Oil ring and ring groove

Oil ring groove width

Oil ring width

Clearance between 2nd ring and ring groove

2nd ring groove width

2nd ring width

Top ring, oil ring end gap

2nd ring end gap

k. Connecting Rod

-

0.014 ~ 0.038 mm

0.00055 ~ 0.00150 in.

23.002 ~ 23.011 mm

0.90560 ~ 0.90594 in.

23.025 ~ 23.040 mm

0.90650 ~ 0.90708 in.

0.05 mm

0.0020 in.

0.15 mm

0.0059 in.

-

-


Connecting rod alignment

Clearance between Piston and small endbushing

Piston pin O.D

Small end bushing I.D

ENGINE SYSTEM

2-13D704-W00 Dec. 2004

l. Crankshaft

-

0.040 ~ 0.118 mm

0.00157 ~ 0.00465 in.

51.921 ~ 51.940 mm

2.04414 ~ 2.04488 in.

51.980 ~ 52.039 mm

2.04646 ~ 2.04878 in.

0.040 ~ 0.104 mm

0.00157 ~ 0.00409 in.

51.921 ~ 51.940 mm

2.04414 ~ 2.04488 in.

51.980 ~ 52.025 mm

2.04646 ~ 2.04823 in.

0.035 ~ 0.093 mm

0.0014 ~ 0.0037 in.

43.959 ~ 43.975 mm

1.73067 ~ 1.73130 in.

44.010 ~ 44.052 mm

1.73268 ~ 1.73433 in.

0.15 ~ 0.31 mm

0.0059 ~ 0.0122 in.

0.08 mm

0.0031 in.

0.20 mm

0.0079 in.

-

-

0.20 mm

0.0079 in.

-

-

0.20 mm

0.0079 in.

-

-

0.5 mm

0.020 in.


Crankshaft alignment

Clearance between Crankshaft and crank-shaft bearing 1

Crankshaft O.D

Crankshaft bearing 1 I.D


Crankshaft O.D


Clearance between Crank pin and Crank pin bearing

Crank pin O.D

Crank pin bearing

I.D

Crankshaft side clearance

B. LUBRICATING SYSTEMa. Oil Pump

more than 68.6 kPa

0.7 kgf/cm2

9.95 psi

294.2 ~ 441 kPa

3.0 ~ 4.5 kgf/cm2

42.7 ~ 64.0 psi

0.10 ~ 0.16 mm

0.0039 ~ 0.0063 in.

0.11 ~ 0.19 mm

0.0043 ~ 0.0078 in.

0.105 ~ 0.150 mm

0.00413 ~ 0.00591 in.

-

294.2 kPa

3.0 kgf/cm2

42.7 psi

0.2 mm

0.0079 in.

0.25 mm

0.0098 in.

0.2 mm

0.00787 in.


Engine oil pressure

(oil temp. 85 ~ 95 °C,

185 ~ 203 °F)

Clearance between inner rotor and outer rotor

Radial clearance between outer rotor and pump

End clearance between inner rotor and cover

At idle speed

At rated speed


2-14 D704-W00 Dec. 2004

C. COOLING SYSTEMa. Thermostat

Valve opening temperature at beginning

Opened completely (height 8 mm 0.315 in.)

69.5 ~ 72.5 °C (157.1 ~ 162.5 °F)

85 °C (185 °F)

b. Radiator

Radiator tightness

Radiator cap tightness

Fan belt tension

[deflection at 78 N (8 kgf, 18 lbs) of force]

No leak at 137 kPa, 1.4 kgf/cm2, 20 psi

10 seconds or more for pressure

falling from 88 ~ 59 kPa

from 0.9 ~ 0.6 kgf/cm2

from 13 ~ 9 psi

7 ~ 9 mm

0.28 ~ 0.35 in.

D. FUEL SYSTEMa. Inject Pump

b. Injection Nozzle

Fuel injection pressure

Fuel tightness of nozzle valve seat

14.709 MPa

150 kgf/cm2

2,134 psi

No fuel leak for 5 sec.

at pressure

12.75 MPa

130 kgf/cm2

1,849 psi

NOTE:• Injection Sequence

Three Cylinders: 1 → 2 → 3(The cylinder number is given in order from the gearcase end.)

Injection timing (BTDC) 20°

ENGINE SYSTEM

2-15D704-W00 Dec. 2004

E. TIGHTENING TORQUESItem

Cylinder head screws

Head cover bolts

* Bearing case screw 1


* Flywheel screw

* Connecting rod screws

Rocker arm support bolts

Drain plug

Glow plugs

Oil switch

Nozzle locating screws

Injection pipe nuts

Size x PitchM11 x 1.25

M6 x 1.0

M9 x 1.25

M10 x 1.25

M12 x 1.25

M8 x 1.0

M10 x 1.25

M12 x 1.25

M10 x 1.25

PT1/8

M20 x 1.5

M12 x 1.5

N•m103.0 ~ 107.9

8.8 ~ 11.8

46.1 ~ 51.0

68.6 ~ 73.6

98.1 ~ 107.9

46.1 ~ 51.0

68.0 ~ 70.6

32.4 ~ 37.3

19.6 ~ 24.5

14.7 ~ 19.6

49.1 ~ 68.7

24.5 ~ 34.3

kgf•m10.5 ~ 11.0

0.9 ~ 1.2

4.7 ~ 5.2

7.0 ~ 7.5

10.0 ~ 11.0

4.5 ~ 5.0

6.2 ~ 7.2

3.3 ~ 3.8

2.0 ~ 2.5

1.5 ~ 2.0

5.0 ~ 7.0

2.5 ~ 3.5

lbf·ft75.9 ~ 79.6

6.5 ~ 8.7

34.0 ~ 37.6

50.6 ~ 54.2

72.3 ~ 79.6

34.0 ~ 37.6

44.8 ~ 52.1

23.9 ~ 37.3

14.5 ~ 18.1

10.8 ~ 14.5

36.2 ~ 50.6

18.1 ~ 25.3

NOTE:• For *marked screw, bolts and nuts on the table,

apply engine oil to their threads and seats beforetightening.

• The letter “M” in Size x Pitch means that the screw,bolt or nut dimension stands for metric. The size isthe nominal outside diameter in mm of the threads.The pitch is the nominal distance in mm betweentwo threads.


2-16 D704-W00 Dec. 2004

Valve Clearance (Cold) IN.

EX.

Valve Seat Angle IN.

EX.

Valve Face Angle IN.

EX.

Valve Recessing

Clearance Between Valve Stem and Valve

Guide

Valve Stem O.D

Valve Stem I.D

3A150F. ENGINE BODYa. Cylinder Head

0.750 ~ 0.9 mm0.0294 ~ 0.0354 in.

When tightened1.17 ~ 1.26 mm

0.0466 ~ 0.0496 in.

3.24 ~ 3.73 MPa

33 ~ 38 kgf/cm2

469 ~ 540 psi

0.05 mm / 100 mm

0.002 in. / 3.94 in.

-

-

2.55 MPa

26 kgf/cm2

370 psi


Cylinder Head Surface Flatness

Top Clearance

Thickness of gasketFree

Compression Pressure(When cranking with starting motor)

* Variance of compression pressure among cylinders should be 10% or less.

b. Valves

0.25 mm 0.0098 in.

0.30 mm 0.0118 in.

0.785 rad. 45°

0.785 rad. 45°

0.785 rad. 45°

0.785 rad. 45°

0.2 ~ 0.5 mm

0.0079 ~ 0.0197 in.

0.040 ~ 0.070 mm

0.0016 ~ 0.0028 in.

7.960 ~ 7.975 mm

0.31339 ~ 0.31398 in.

8.015 ~ 8.030 mm

0.3156 ~ 0.3161 in.

0.8 mm

0.0315 in.

0.10 mm

0.0039 in.

-

-


c. Valve Timing

0.14rad 8° before T.D.C

0.611rad 35° after B.D.C

0.785rad 45° before B.D.C

0.140rad 8° after T.D.C


Inlet Valve Open

Close

Exhaust Valve Open

Close

-

-

ENGINE SYSTEM

2-17D704-W00 Dec. 2004

d. Cylinder Bore

Cylinder bore innerdiameter

83.000 ~ 83.022 mm

3.2677 ~ 3.2690 in.

0.15 mm

0.0059 in.

e. Valve Spring

41.7 ~ 42.2 mm

1.6417 ~ 1.6614 in.

12.0 kgf / 35.15 mm

26.5 lbs / 1.3839 in.

-

41.2 mm

1.6220 in.

10.2 kgf / 35.15 mm

22.5 lbs / 1.3839 in.

1.0 mm

0.039 in.


f. Rocker Arm

18.955 ~ 18.980 mm

0.7463 ~ 0.7472 in.

19.000 ~ 19.025 mm

0.7480 ~ 0.7490 in.

-

-


Rocker arm shaft O.D

Rocker arm bushing I.D

g. Tappet

0.020 ~ 0.062 mm

0.00079 ~ 0.00244 in.

23.959 ~ 23.980 mm

0.94327 ~ 0.94410 in.

24.000 ~ 24.021 mm

0.94488 ~ 0.94571 in.

0.07 mm

0.0028 in.

-

-


Clearance between tappet and guide

Tappet O.D

Tappet guide I.D

h. Camshaft

0.01 mm

0.0004 in.

33.9 mm

1.3224 in.

33.69 mm

1.326 in.

0.050 ~ 0.091 mm

0.00197 ~ 0.00358 in.

39.934 ~ 39.950 mm

1.57220 ~ 1.57283 in.

40.000 ~ 40.025 mm

1.57480 ~ 1.57579 in.

0.05 mm

0.0020 in.

33.54 mm

1.3205 in.

33.64 mm

1.3244 in.

0.15 mm

0.0059 in.

39.88 mm

1.5701 in.

-


Camshaft alignment

Cam height IN.

EX.

Clearance between camshaft

Camshaft journal O.D

Camshaft counter bore I.D

Free length

Assembling load / assembling length

Squareness



2-18 D704-W00 Dec. 2004

I. Timing Gear

0.04 ~ 0.11 mm

0.0016 ~ 0.0043 in.

0.20 ~ 0.51 mm

0.0079 ~ 0.0201 in.

0.025 ~ 0.066 mm

0.00098 ~ 0.00250 in.

37.9590 ~ 37.9950 mm

1.49445 ~ 1.49508 in.

38.000 ~ 38.025 mm

1.49608 ~ 1.49705 in.

0.15 mm

0.0059 in.

0.9 mm

0.035 in.

0.1 mm

0.0039 in.

-

-


Timing gear backlash

Idle gear side clearance

Clearance between Idle gear shaft and idlegear bushing

Idle gear shaft O.D

Idle gear bushing I.D

j. Piston Ring

25.00 ~ 25.006 mm

0.98425 ~ 0.98448 in.

0.020 ~ 0.060 mm

0.00079 ~ 0.00236 in.

5.01 ~ 5.03 mm

0.19724 ~ 0.19803 in.

5.97 ~ 5.99 mm

0.23504 ~ 0.23583 in.

0.065 ~ 0.100 mm

0.00256 ~ 0.00394 in.

2.055 ~ 2.070 mm

0.08091 ~ 0.08150 in.

1.97 ~ 1.99 mm

0.07756 ~ 0.07834 in.

0.25 ~ 0.40 mm

0.0098 ~ 0.01570 in.

0.25 ~ 0.40 mm

0.0098 ~ 0.01570 in.

25.03 mm

0.9854 in.

0.15 mm

0.0059 in.

-

-

0.15 mm

0.0059 in.

-

-

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.


Piston pin-bore I.D

Clearance between Oil ring and ring groove

Oil ring groove width

Oil ring width

Clearance between 2nd ring and ring groove

2nd ring groove width

2nd ring width

Top ring, oil ring end gap

2nd ring end gap

k. Connecting Rod

-

0.014 ~ 0.038 mm

0.00055 ~ 0.00150 in.

25.002 ~ 25.011 mm

0.98433 ~ 0.98469 in.

25.025 ~ 25.040 mm

0.98524 ~ 0.98583 in.

0.05 mm

0.0020 in.

0.15 mm

0.0059 in.

-

-


Connecting rod alignment

Clearance between Piston and small endbushing

Piston pin O.D

Small end bushing I.D

ENGINE SYSTEM

2-19D704-W00 Dec. 2004

l. Crankshaft

-

0.040 ~ 0.118 mm

0.00157 ~ 0.00465 in.

51.921 ~ 51.940 mm

2.04414 ~ 2.04488 in.

51.980 ~ 52.039 mm

2.04646 ~ 2.04878 in.

0.040 ~ 0.104 mm

0.00157 ~ 0.00409 in.

51.921 ~ 51.940 mm

2.04414 ~ 2.04488 in.

51.980 ~ 52.025 mm

2.04646 ~ 2.04823 in.

0.035 ~ 0.093 mm

0.0014 ~ 0.0037 in.

43.959 ~ 43.975 mm

1.73067 ~ 1.73130 in.

44.010 ~ 44.052 mm

1.73268 ~ 1.73433 in.

0.15 ~ 0.31 mm

0.0059 ~ 0.0122 in.

0.08 mm

0.0031 in.

0.20 mm

0.0079 in.

-

-

0.20 mm

0.0079 in.

-

-

0.20 mm

0.0079 in.

-

-

0.5 mm

0.020 in.


Crankshaft alignment


Crankshaft O.D



Crankshaft O.D


Clearance between Crank pin and Crank pin bearing 2

Crank pin O.D

Crank pin bearing

I.D

Crankshaft side clearance

G. LUBRICATING SYSTEMa. Oil Pump

more than 68.6 kPa

0.7 kgf/cm2

9.95.11 psi

245.1 kPa

2.5 kgf/cm2

35.5 psi

0.10 ~ 0.16 mm

0.0039 ~ 0.0063 in.

0.11 ~ 0.19 mm

0.0043 ~ 0.0078 in.

0.105 ~ 0.150 mm

0.00413 ~ 0.00591 in.

-

294.2 kPa

3.0 kgf/cm2

42.7 psi

0.2 mm

0.0079 in.

0.25 mm

0.0098 in.

0.2 mm

0.00787 in.


Engine oil pressure

(oil temp. 85 ~ 95 °C,

185 ~ 203 °F)

Clearance between inner rotor and outer rotor

Radial clearance between outer rotor and pump

End clearance between inner rotor and cover

At idle speed

At rated speed


2-20 D704-W00 Dec. 2004

H. COOLING SYSTEMa. Thermostat

Valve opening temperature at beginning

Opened completely (height 8 mm 0.315 in.)

69.5 ~ 72.5 °C (157.1 ~ 162.5 °F)

85 °C (185 °F)

b. Radiator

Radiator tightness

Radiator cap tightness

Fan belt tension

[deflection at 78 N (8 kgf, 18 lbs) of force]

No leak at 137 kPa, 1.4 kgf/cm2, 20 psi

10 seconds or more for pressure

falling from 88 ~ 59 kPa

from 0.9 ~ 0.6 kgf/cm2

from 13 ~ 9 psi

7 ~ 9 mm

0.28 ~ 0.35 in.

I. FUEL SYSTEMa. Inject Pump

b. Injection Nozzle

Fuel injection pressure

Fuel tightness of nozzle valve seat

14.709 MPa

150 kgf/cm2

2,134 psi

No fuel leak for 5 sec.

at pressure

12.75 MPa

130 kgf/cm2

1,849 psi

NOTE:• Injection Sequence

Three Cylinders: 1 → 2 → 3(The cylinder number is given in order from the gearcase end.)

Injection timing (BTDC) 18°

ENGINE SYSTEM

2-21D704-W00 Dec. 2004

J. TIGHTENING TORQUESItem

Cylinder head screws

Head cover bolts



* Flywheel screw

* Connecting rod screws

Rocker arm support bolts

Drain plug

Glow plugs

Oil switch

Nozzle locating screws

Injection pipe nuts

Size x PitchM11 x 1.25

M8 x 1.0

M9 x 1.25

M10 x 1.25

M12 x 1.25

M8 x 1.0

M10 x 1.25

M12 x 1.25

M10 x 1.25

PT1/8

M20 x 1.5

M12 x 1.5

N•m103.0 ~ 107.9

8.8 ~ 11.8

46.1 ~ 51.0

68.6 ~ 73.6

98.1 ~ 107.9

46.1 ~ 51.0

60.8 ~ 70.6

32.4 ~ 37.3

19.6 ~ 24.5

14.7 ~ 19.6

49.1 ~ 68.7

24.5 ~ 34.3

kgf•m10.5 ~ 11.0

0.9 ~ 1.2

4.7 ~ 5.2

7.0 ~ 7.5

10.0 ~ 11.0

4.5 ~ 5.0

6.2 ~ 7.2

3.3 ~ 3.8

2.0 ~ 2.5

1.5 ~ 2.0

5.0 ~ 7.0

2.5 ~ 3.5

lbf·ft75.9 ~ 79.6

6.5 ~ 8.7

34.0 ~ 37.6

50.6 ~ 54.2

72.3 ~ 79.6

34.0 ~ 37.6

44.8 ~ 52.1

23.9 ~ 37.3

14.5 ~ 18.1

10.8 ~ 14.5

36.2 ~ 50.6

18.1 ~ 25.3

NOTE:• For *marked screw, bolts and nuts on the table,

apply engine oil to their threads and seats beforetightening.

• The letter “M” in Size x Pitch means that the screw,bolt or nut dimension stands for metric. The size isthe nominal outside diameter in mm of the threads.The pitch is the nominal distance in mm betweentwo threads.


2-22 D704-W00 Dec. 2004

7. DISASSEMBLING AND MAINTENANCE

7.1 DISASSEMBLING ENGINE

To avoid personal injury:• Be sure to stop the engine before changing the oil.• Allow engine to cool down sufficiently, oil can be

hot and can burn.

CAUTION

A. DRAINING THE ENGINE OIL

(1) Oil Inlet

(2) Dipstick

(A) Oil Level is Acceptable Within this Range

704W306A

(1) Drain Plug

1. To drain the used oil, remove the drain plug at thebottom of the engine and drain the oil completelyinto the oil pan.

All the used oil can be drained out easily when theengine is still warm.

2. After draining reinstall the drain plug.

3. Fill with the new oil up to the upper notch on thedipstick.

Oil capacitywith filter

CH25(H)

CK30(H)5.8

(1.53 U.S.gal.)

704W307A

ENGINE SYSTEM

2-23D704-W00 Dec. 2004

1. Stop the engine and let it cool down.

2. After open the bonnet

3. To drain the coolant, open the radiator drain plugand remove radiator cap. The radiator cap must beremoved to completely drain the coolant.

4. After all coolant is drained, close the drain plug.

(Filling)

• Fill water up the point between “Full” and “Low” markon the recovery water tank.

(1) Drain Plug

(1) Radiator Cap (A) FULL

(2) Recovery Tank (B) LOW

704W144A

704W143A

• Never open radiator cap when the coolant’stemprature reaches boiling point.

• Do not remove the radiator cap when the engineis hot. Then loosen cap slightly to the stop. Re-lieve any excess pressure before removing capcompletely.

CAUTION

Coolantcapacity

7.4 (2.0 U.S.gal.)CK25

CK30 7.8 (2.1 U.S.gal.)

B. DRAINING THE COOLANT

C. BONNET1. Open the bonnet (1) and disconnect the electronic

connector (2).

2. Remove the air-cylinder (3).

3. Remove the snap-pin, joint-pin and bonnet(1).

4. Remove the side cover (LH/RH) (4).

5. Disconnect the battery terminal (-) (5).

NOTE:• When disconnecting the battery cords, disconnect

the (-) cord first. Connecting, (+) cable first.

(For assembly)After connecting the battery terminal (-), apply a littlegrease to it.

704W308A

(1) Bonnet (4) Side Cover

(2) Connector (5) Battery terminal (-)

(3) Air-cylinder


2-24 D704-W00 Dec. 2004

Tightening torque

9.8 N·m

1.0 kgf·m

7.2 lb·ft

9.8 N·m

1.0 kgf·m

7.2 lb·ft

Item

Steering hose P, R, L

Pipe bed

D. HYDRAULIC PIPE AND ELECTRIC WIRING1. Remove the engine stop wire.(1)

2. Remove the steering hoses(R, P, T).(2, 3, 4).

3. Remove the accelerator wires (hand, pedal).(5, 6)

4. Disconnect the bonnet wire harness 2 Assy.

5. Remove the rubber pipe 1 (7) out of suction pipe 3(8).

6. Remove the hydraulic pipe (B1).(9)

7. Remove the cooling pipe 3 (HST type)

8. Remove the steering hose (L).(10)

9. Remove the cooling pipe 4 (HST type)

10. Disconnect the bonnet wire harness 1 Assy.(11)

704W310A

(When reassembling)• A hose classification

- Steering hose P : A red tag attachment

- Steering hose R : A white tag attachment

- Steering hose L : A yellow tag attachment

- Steering hose T : No tag

704W309A

(1) Engine stop wire (7) Rubber pipe

(2) Steering hose (R) (8) Suction pipe 3

(3) Steering hose (P) (9) Hydraulic pipe (B1)

(4) Steering hose (T) (10) Steering hose (L)

(5) Accelerator wire(hand)(11) Bonnet wire harness

(6) Accelerator wire(pedal) 1 Assy

ENGINE SYSTEM

2-25D704-W00 Dec. 2004

E. PROPELLER SHAFT1. Remove the bolts and slide the propeller shaft cover .

2. Tap out the spring pin (8), and then slide the cou-pling (2) to the rear.

3. Romove the propeller shaft and cover.

(When reassembling)• Apply grease to the splines of the propeller shaft.

(1) Propeller Shaft

(2) Coupling

(3) Cir-Clip

(4) Propeller Shaft Cover 1

(5) Propeller Shaft Cover 2

704W311A

(6) O-Ring

(7) O-Ring

(8) Spring Pin

(9) O-Ring

(10) Bolt

704W312A

F. SEPARATING ENGINE & CLUTCH HOUS-ING1. Place the jacket to the bottom of the clutch housing

and engine.

2. Remove the mounting bolts for the fuel tank support.

3. Separate engine and clutch housing.

(When reassembling)• Apply grease to the spline of main shaft.

• Apply liquid gasket (Three Bond 1,211 or equivalent)to the joint face of the flywheel housing and clutchhousing.

Tightening torque

48.1 ~ 55.9 N·m

4.9 ~ 5.7 kgf·m

1.004 ~ 1.167 lb·ft

24.5 ~ 31.4 N·m

2.5 ~ 3.2 kgf·m

0.512 ~ 0.655 lb·ft

Item

Bolts, nuts

Stud Bolts


2-26 D704-W00 Dec. 2004

H. SEPARATING THE FUEL TANK1. Remove the bonnet wire-harness1(1).

2. Remove the air cleaner(2).

3. Remove the reovery tank(3).

4. Loosen bolts and remove the fuel tank(4).

5. Remove the muftler(5).

6. Remove the bonnet wire harness2(6).

7. Remove the water pipe(7, 8)

704W313A

G. REMOVING CLUTCH1. Put alignment marks on the clutch cover and fly

wheel. (CK25/30)

2. Insert the clutch center tool.

3. Remove the clutch assembly.

(1) Bonnet Wire Harness 1(5) Muftler

(2) Airr Cleaner (6) Bonnet Wire Harness2

(3) Recovery Tank (7) Water Pipe(Upper)

(4) Fuel Tank (8) Water Pipe(Lower)

704W312A

ENGINE SYSTEM

2-27D704-W00 Dec. 2004

J. DISASSEMBLING OTHER ENGINE PARTS.

1. Remove the gear pump assy(1) and pump holder.

2. Remove the fan belt(2), cooling fan(3) and fan pulley.

3. Remove the dynamo assy(4).

4. Remove the start motor(5).

704W313A

I. DISASSEMBLING FRONT AXLE FRAME1. Lift engine with chain hook and support it.

2. Loosen bolts and remove the engine from the frontaxle frame.

704W312A

(1) Gear Pump (4) Dynamo Assy

(2) Fan Belt (5) Starter Motor

(3) Cooling Fan

Tightening torque

60.9 ~ 70.6 N·m

6.2 ~ 7.2 kgf·m

44.9 ~ 52.0 lb·ft

103 ~ 117 N·m

10.5 ~ 12.0 kgf·m

76.0 ~ 86.7 lb·ft

Item

M10 Bolt

(Only CK30)

M12 Bolts

ENGINE SYSTEM

2-29D704-W00 Dec. 2004

704W243A

7.2. ENGINE DISASSEMBLED VIEW

(1) Cylinder Block(2) Oil Pressure Switch(3) Oil Pump(4) Oil Pan(5) Oil Strainer(6) Oil Gauge

(7) Cylinder Head(8) Head Bolt(9) Gear case

(10) Oil Filter(11) Main bearing Case

Cover

(12) Bearing Case Bolt 1(13) Main Bearing Case(14) Bearing Case Bolt 2(15) Rocker Arm(16) Inlet, Exhaust Valve(17) Cylinder Hear Cover

(18) Push Rod(19) Tappet(20) Camshaft(21) Camshaft Gear(22) Idle Gear(23) Piston

(24) Connecting Rod(25) Crankshaft(26) Flywheel(27) Flywheel Housing(28) Starter(29) Injection Pipe

(30) Glow Plug(31) Nozzle(32) Fuel Injection Pump(33) Fuel Feed Pump(34) Fuel Camshaft(35) Fuel Camshaft Gear

(36) Engine Stop Solenoid(37) Speed Control Plate(38) Fork Lever (Governor)(39) Impeller(40) Thermostat(41) Alternator

(42) Fan Drive Pulley(43) Cooling Fan(44) Radiator(45) Reserve Tank Ass’y(46) Inlet Manifold(47) Muffler

(48) Exhaust Manifold(49) Air Cleaner

ENGINE SYSTEM

2-31D704-W00 Dec. 2004

704W248A

A. CHECKING AND ADJUSTINGa. Compression pressure1. Run the engine until warmed up.

2. Stop the engine and remove the air cleaner, themuffler and all nozzle holders.

3. Connect a compression tester to the nozzle holderhole.

4. Pull the stop lever to cut the fuel and run the enginewith the starter at 250 ~ 350 rpm for 5 ~ 10 seconds.

5. Measure the maximum pressure while running, sev-eral times.

6. If the pressure does not reach the allowable limit,apply a small amount of oil to the cylinder wallthrough the nozzle holder hole and check the pres-sure again.

7. If the pressure raises after oil is apply, check thecylinder wall and piston ring.

8. If the pressure is still low, check the top clearance,valve clearance and cylinder head.

NOTE:• Check the compression pressure with the specified

valve clearance for proper air in taking.

Compressionpressure

Differencebetween twocylinders

Factory spec.

Allowable limit

Allowable limit

3.24 ~ 3.73 MPa

33 ~ 38 kgf/cm2

470 ~ 541 psi

2.55 MPa

26 kgf/cm2

370 psi

10 %

7.3 ENGINE BODY


2-32 D704-W00 Dec. 2004

704W251A

704W250A

704W249A

(1) Injection Nozzle (3) Heat Seal

(2) Gasket

B. DISASSEMBLING AND ASSEMBLINGa. Cylinder head cover, glow plugs and fuel

overflow pipes.1. Remove the injection pipes and over flow pipe.

2. Remove the glow plugs.

3. Remove the injection nozzles, gaskets, and heatseals.

4. Remove the cylinder head cover.

(When reassembling)

• Check that the cylinder head cover gasket is notdefective.

• Tighten the cylinder head cover cap nuts in severalsteps.

b.Valve clearance1. Remove the cylinder head cover and the timing win-

dow cover on the flywheel housing and all glow plugs.

2. Turn the flywheel and align the 1 TC mark mark withthe timing mark of window on the flywheel housing.This will position the 1st cylinder valves at the topdead center during compression stroke.

3. Measure the clearance at the valves marked with in the table below with a feeler gauge.

4. I f the clearance is not within the factoryspecifications, turn the adjusting screw to adjust.

5. Turn the flywheel just one turn to position the 1stcylinder valves at the top head center during overlap.

6. Measure the clearance at the valves marked with in the table below with a feeler gauge.

7. If the clearance is not within spec. ; adjust. Seeabove.

Factory spec. 3A150 In. : 0.25 mm 0.0098 in.

Ex. : 0.30 mm 0.0118 in.

Cylinder NO.

Valve

Checking

1

IN. EX.

2

IN. EX.

3

IN. EX.

TD1300 In. : 0.1 mm 0.0039 in.

Ex. : 0.1 mm 0.0039 in.

(A) Gear Case

ENGINE SYSTEM

2-33D704-W00 Dec. 2004

704W254A

704W253A

704W252A

(1) Philips Screw Driver (2) Nozzle

(3) Injection Nozzle Gasket (4) Heat Seal

(1) Rocker Arm Shaft (3) Rocker Arm Bracket

(2) Rocker Arm (4) Bolt

b. Heat seal removal procedure1. Drive screw driver lightly into the heat seal hole.

2. Turn screw driver three or four times each way.

3. While turning the screw driver, slowly pull the heatseal and the injection nozzle gasket. If the heat sealdrops, repeat the above procedure.

4. The heat seal and injection nozzle gasket must bechanged when the injection nozzle is removed forcleaning or for service.

NOTE:• Use a philips screw driver that has a diameter

which is bigger than the heat seal hole 1/4 in.(approx. φ 6mm).

c. Rocker arm assembly1. Loosen the bolts in several steps and the specified

sequence shown in the figure and remove them.

• To loosen (3) to (1)

• To tighten (1) to (3)

2. Remove the rocker arm assembly and the push rod.

(When reassembling)

• Rest the end of push rod at the indent of tappet andinstall the rocker arm assembly.

• Tighten the bolts in several steps and in the speci-fied sequence to the specified torque. Refer to thefigure.

• Adjust the valve clearance after assembling therocker arm assembly.

(A) Gear Case

Tighteningtorque

60.8 ~ 70.6 N·m

6.2 ~ 7.2 kgf·m

44.8 ~ 52.1 lbf·ft

3A150

TD1300 29.4 ~ 34.3 N·m

3.0 ~ 3.5 kgf·m

21.7 ~ 25.3 lbf·ft

2 1 3


2-34 D704-W00 Dec. 2004

704W257A

704W256B

d. Cylinder head1. Remove the screw in the specified sequence shown

in the figure and remove the cylinder head (1) andhead gasket.

• To loosen (14) to (1)

• To tighter (1) to (14)

2. Remove the water flange (2).

3. Take out the tappets from the cylinder block.

NOTE:• Mark the cylinder number to the tappets to prevent

interchanging.

(When reassembling)

• Apply liquid gasket (Three bond 1215 or equivalent)on the both sides of the water flange gasket.

• Replace the head gasket with a new one and placeon the cylinder block, be careful of its direction andside.

• When using the head gasket shim, install the shimon the cylinder head prior to the gasket.

• Before installing the tappets apply engine oil aroundthem.

IMPORTANT:• Apply oil to the thread of screws and tighten in sev-

eral steps and the specified sequence shown in thefigure to the specified torque.

• Check the torque after 30 minutes operation of theassembled engine, and adjust valve clearance.

(1) Cylinder Head (2) Water Flange

e. Valve1. Compress the valve spring and remove the collect

(2).

2. Remove the retainer (3), valve spring (4), valve stemseal (5) and the valve (1).

IMPORTANT:• Do not interchange valves and valve parts.

• Mark the cylinder number on the valve and the partsto prevent interchanging.

(When reassembling)

• Apply oil to the stem of valve and install in the cylin-der head.

• Lubricate the valve and the parts after reassem-bling. (1) Valve (4) Valve Spring

(2) Collect (5) Valve Stem Seal

(3) Retainer

(A) Gear Caser

1

2

704W255A

Tighteningtorque

3A150 103.0 ~ 107.9 N·m10.5 ~ 11.0 kgf·m75.9 ~ 79.6 lbf·ft

TD1300 78.5 ~ 83.4 N·m8.0 ~ 8.5 kgf·m

57.9 ~ 61.5 lbf·ft

ENGINE SYSTEM

2-35D704-W00 Dec. 2004

704W260A

704W258A

b. Governor spring and Speed control plate1. Disconnect the governor spring 1 (1) and 2 (2) from

the governor lever (4).

2. Remove the speed control plate.

3. Remove the governor spring.

(When reassembling)

• Be careful not to drop the governor springs 1, 2 intothe gear case.

• Fix the governor springs (1), (2) to the fork lever 2(3) and pull the springs. Hook springs on to thegovernor lever (4).

• Apply a liquid gasket both side of speed control plategasket.

C. TIMING GEARS AND CAMSHAFTSa. Injection pump1. Remove the injection pump cover (3) with the en-

gine stop lever (2).

2. Remove the injection pump.

(When reassembling)

• Apply liquid gasket to the both sides of injection pumpcover gasket and install it.

• Install the injection pump so that its control rack pin(4) engages with the groove (5) of fork lever 1 (1).

• Install the injection pump cover with the arm of en-gine stop lever (2) at the right of the arm of the forklever 1 (1). (1) Fork Lever 1 (4) Control Rack Pin

(2) Engine Stop Lever (5) Groove

(3) Injection Pump Cover (6) Shim

(1) Governor Spring 1 (3) Fork Lever 2

(2) Governor Spring 2 (4) Governor Lever

704W259A


2-36 D704-W00 Dec. 2004

704W261A

704W262A

e. Gear case1. Remove the gear case.

(When reassembling)

• Stick the O-ring (1) to the gear case with thin greaseto prevent from coming off during reassembling.

• Apply grease to the crankshaft oil seal lip on the gearcase and take care not to damage it when installing.

• Apply liquid gasket (three bond 1215 or equivalent)to the both sides of gear case gasket.

(1) O-Ring

c. Start spring1. Remove the start spring (1) from the fork lever 1 (2).

(When reassembling)

• Be careful not to drop the start spring into the gearcase.

• Hook the start spring so that the longer hook is onthe fork lever side.

d. Fan drive pulley1. Install the stopper into the flywheel, so that the crank-

shaft may not turn.

2. Flatten the metal lock and loosen the crankshaft nut(2).

3. Remove the fan drive fan drive pulley (1).

(1) Fan Drive Pulley (2) Crankshaft Nut

Tighteningtorque

137.3 ~ 156.9 N·m

14.0 ~ 16.0 kgf·m

101.3 ~ 115.7 lbf·ft

Crankshaftnut

(1) Start Spring (2) Fork Lever 1

704W263A

ENGINE SYSTEM

2-37D704-W00 Dec. 2004

704W265A

704W264A

f. Water pump and relief valve1. Remove the water pump body (1) from the gear case.

g. Idle gear and crank gear1. Remove the crankshaft collar (6), O-ring (5), oil

slinger (4) and crank gear collar (3) in the order.

2. Remove the idle gear (1).

3. Remove the crankshaft gear (2) with a special usepuller set.

(When reassembling)

• Heat the crankshaft gear to approx. 80 °C (176 °F)and insert the crankshaft.

• Apply oil to the O-ring (5).

(1) Water Pump Body (2) Relief Valve Cover

IMPORTANT:• Install the idle gear, aligning the alignment marks

referring to the figure.

(1) Idle Gear (6) Crankshaft Collar

(2) Crankshaft Gear (7) Oil Pump Gear

(3) Crank Gear Collar (8) Injection Pump Gear

(4) Oil Slinger (9) Cam Gear

(5) O-Ring

91

2

7

8

704W266A


2-38 D704-W00 Dec. 2004

704W268A

h. Camshaft1. Align the holes on the cam gear (2) with the crews.

Loosen them through the holes with a T handlewrench.

2. Draw out the camshaft (1).

3. Remove the cam gear (2).

(When reassembling)

• Heat the cam gear to approx. 80°C (176°F) and in-sert the camshaft (1).

i. Fuel camshaft1. Remove the fuel camshaft stopper.

2. Loosing the fork lever holder screws, remove thefuel camshaft (4) with fork lever holder (5), fork lever1 (1) and 2 (2).

3. Remove the Injection pump gear (3).

(When reassembling)

• Heat the injection pump gear to approx. 80°C(176°F) and insert the camshaft (4).

(1) Fork Lever 1 (4) Camshaft

(2) Fork Lever 2 (5) Fork Lever Holder

(3) Injection Pump Gear

(1) Camshaft (2) Cam Gear

704W267A

ENGINE SYSTEM

2-39D704-W00 Dec. 2004

b. Piston and connecting rod1. Remove the screws and the connecting rod cap.

2. Push out the rod and piston assembly.

(When reassembling)

• Apply oil to the crankpin bearing, cylinder wall andconnecting rod cap screw.

• Insert the connecting rod and piston assembly withthe mark on the rod facing the injection pump, us-ing a piston ring compressor.

IMPORTANT:• Mark the cylinder number on the piston and con-

necting rod to prevent interchanging.

• Carefully insert the piston and ring assembly in thecylinder. Be careful when compressing the rings notto damage the chrome-plate on the piston rings.

• If the connecting rod cap screws can not be screwedto the end by hand, replace the screw.

704W270A

704W269A

D. CONNECTING ROD AND PISTONa. Oil pan and oil filter1. Remove the oil pan.

2. Remove the oil strainer (1).

(When reassembling)

• Be sure to install the O-ring (2) between the oilstrainer and the cylinder block.

(1) Oil Strainer (2) O-Ring


2-40 D704-W00 Dec. 2004

704W273A

704W272A

c. Piston ring and piston pin1. Remove the piston rings with a piston ring replac-

ing tool.

2. Remove the piston pin.

(When reassembling)

• Clean all the parts before assembling.

• Heat the piston in approx. 80 °C (176 °F) of oil for 10~ 15 minutes, when inserting the piston pin into thepiston.

• Install the piston and connecting rod with the markFW on the piston towards the flywheel and the markon connecting rod towards the injection pump.

• Install the piston rings with their manufacture’smark to the top of piston.

• Install the expander in the oil ring with its gap oppo-site to the gap of oil ring.

• Install the top ring with its gap at 1.57 rad (90 °) fromthe piston pin to the exhaust port.

• Install the second ring and the oil ring with their gapat every 2.09 rad (120 °).

(7) Connecting Rod (11) Expander Joint

(8) Connecting Rod Cap (12) Oil Ring Gap

(9) Casting Mark (13) Manufacturer’s Mark

(10) Marks

704W271A

(1) Piston Pin

(2) Piston

(3) Piston Pin Snap Ring

(4) Top Ring

(5) Second Ring

(6) Oil ring

(7) Connecting Rod

ENGINE SYSTEM

2-41D704-W00 Dec. 2004

E. CRANKSHAFTa. Flywheel1. Install the stopper to the flywheel and loosen the

screw.

2. Remove the flywheel stopper and the flywheel.

(When reassembling)

• Clean the end of the crankshaft and the mating sur-face of the flywheel.

• Apply oil to flywheel screws.

• Fit the flywheel hole to crankshaft hole and tightenthe flywheel bolts to specified torque.

NOTE:• Screw longer screws to the flywheel to carry It if

needed.

Tighteningtorque

Flywheelscrew

98.1 ~ 107.9 N·m

10.0 ~ 11.0 kgf·m

72.3 ~ 79.6 lbf·ft

704W274A

b. Bearing case coverLoosen the screw first inside and next outside, and liftthe cover (1) by screwing the two screws gradually andevenly, referring to the photo.

(When reassembling)

• Apply grease to the oil seal lip. Take care that the lipseal is is not rolled while installing.

704W275A

Tighteningtorque

Bearingcase

cover screw

23.5 ~ 27.5 N·m

2.4 ~ 2.8 kgf·m

17.4 ~ 20.3 lbf·ft

(1) Bearing Case Cover

704W276A

c. Crankshaft1. Remove the bearing case screw 2.

2. Pull out the crankshaft, taking care not to damagethe crankshaft bearing 1.

(When reassembling)

• Apply oil to the bearing case screw 2.

• Clean the oil passage of the crankshaft with com-pressed air.

Bearingcasescrew 2

3A150 68.7 ~ 73.6 N·m

7.0 ~ 7.5 kgf·m

50.6 ~ 54.2 lbf·ft

(1) Bearing Case Scraw 2TD1300 63.8 ~ 68.7 N·m

6.5 ~ 7.0 kgf·m

47.0 ~ 50.6 lbf·ft


2-42 D704-W00 Dec. 2004

704W278A

IMPORTANT:• Mark the location line to the bearing case, to pre-

vent interchanging.

(When reassembling)

• Clean the parts and the oil passage of the bearingcase.

• Apply oil to the journal, bearing inserts and the bear-ing case screws.

• Place the thrust bearings on the bearing case withtheir oil groove outside.

• Install the main bearing case with the mark “FLYWHEEL” toward the flywheel.

(6) Bearing CaseBearingcasescrew 1

3A150 46.1 ~ 51.0 N·m

4.7 ~ 5.2 kgf·m

34.0 ~ 37.6 lbf·ftTD1300 29.4 ~ 34.3 N·m

3.0 ~ 3.5 kgf·m

21.7 ~ 25.3 lbf·ft

704W277A

d. Main bearing case1. Remove the bearing case screws 1 (4) and remove

the main bearing case 1, 2, 3 (1,2,3).

2. Remove the thrust bearing from the flywheel endbearing case.

(1,2,3) Main Bearing Case Assembly 1, 2, 3

(4) Bearing Case Screw 1

(5) Thrust Bearings

ENGINE SYSTEM

2-43D704-W00 Dec. 2004

704W279A

F. SERVICINGa. Cylinder head and valve(A) Cylinder head surface flatness

1. Thoroughly clean the cylinder head surface.

2. Place a straight edge on the cylinder head and mea-sure the clearance with a feeler gage as shown inthe figure.

3. If the measurement exceeds the allowable limit, re-place the cylinder head.

IMPORTANT:• Do not place the straight edge on the combustion

chamber.

Flatness Allowablelimit

0.05 mm

0.002 in.

704W280A

(B) Cylinder head surface flaw

1. Prepare an air spray red check.

2. Clean the cylinder head surface with the detergent(B).

3. Spray the cylinder head surface with the red perme-ative liquid (A).

4. Wash away the red permeative liquid on the cylin-der head surface with the detergent (B) after ten min-utes.

5. Spray the cylinder head surface with the white de-veloper (C).

6. If any flaw is found such as a red mark, replace thecylinder head.

(A) Red Permeative Liquid

(B) Detergent

(C) White Developer


2-44 D704-W00 Dec. 2004

704W282A

(D)Valve recessing

1. Clean the cylinder head, the valve face and the seat.

2. Insert the valve in the guide.

3. Measure the valve recessing with a depth gauge.

4. If the recessing exceeds the allowable limit, replacethe valve and check the valve seating.

Valverecessing

Factoryspec.

0.2 ~ 0.5 mm

0.0079~ 0.0197 in.

1.1 ~ 1.3 mm

0.0433 ~ 0.0512 in.

3A150

TD1300

Allowablelimit

0.8 mm

0.0315 in.

1.6 mm

0.0630 in.

3A150

TD1300

1211

107

82

10

65

43

9

(C)Valve stem clearance

1. Remove the carbon from the valve guide.

2. Measure the valve stem O.D. with an outsidemicrometer.

3. Measure the valve guide I.D. of cylinder head, andcalculate the clearance.

4. If the measurement exceeds the allowable limit, re-place the valve guide of the valve.

704W281A

Valve stemclearance

Factoryspec.

0.040 ~ 0.070 mm

0.00157 ~ 0.00276 in.

0.025 ~ 0.055 mm

0.00098 ~ 0.00216 in.

3A150

TD1300

Allowable limit 0.1 mm

0.004 in.Valve guidebore I.D.

Factoryspec.

8.015 ~ 8.030 mm

0.31555 ~ 0.31614 in.

8.0 ~ 8.015 mm

0.31496 ~ 0.31555 in.

3A150

TD1300

Factoryspec.

7.960 ~ 7.975 mm

0.31339 ~ 0.31398 in.

Valve stemO.D.

ENGINE SYSTEM

2-45D704-W00 Dec. 2004

704W283A

(E) Valve seat

1. Coat the valve face lightly with red lead and put thevalve on its seat to check the contact.

2. If the valve does not seat all the way around the valveseat or the valve contact is less than 70%, correctthe valve seating as follows.

3. Apply compound on the valve face evenly.

4. Put the valve on its seat hold it with the valve flapper.

5. Turn and lap the valve back and forth on the valveseat to lap.

6. Remove the compound and clean the valve and theseat.

7. Apply oil on the valve face and finish to completefitting.

8. Repeat lapping until the valve seats correctly.

704W284A

(F) Valve spring

1. Measure the free length of the spring with venirecalipers.

2. Place the spring on a spring compression tester and com-press to the specified length, and get the tension.

3. If the measurement is less than the allowable limit,replace the valve spring.

Freelength

Factoryspec.

Allowablelimit

Factoryspec.

Allowablelimit

17.7 N / 35.15 mm

12.0 kgf / 35.15 mm

26.5 lbs / 1.3839 in.

100 N / 35.15 mm

10.2 kgf / 35.15 mm

22.5 lbs / 1.3839 in.

41.7 ~ 42.2 mm

1.6417 ~ 1.6614 in.

41.2 mm

1.622 in.

Tension


2-46 D704-W00 Dec. 2004

11

10

9

704W286A

(H)Rocker arm bushing and shaft clearance

1. Measure the rocker arm I.D. with an inside micrometer.

2. Measure the rocker arm shaft O.D. with an outsidemicrometer.

3. If the clearance exceeds the allowable limit, replacethe rocker arm.

4. If the clearance still exceeds the allowable limit afterreplacing the rocker arm replace the rocker arm shaft.

Clear-ance

Factoryspec.

0.020 ~ 0.070 mm

0.00079 ~ 0.00276 in.

0.014 ~ 0.050 mm

0.00055 ~ 0.00197 in.

3A150

TD1300


0.0059 in.Rockerarm shaftO.D.

Factoryspec.

18.955 ~ 18.980 mm

0.74626 ~ 0.74724 in.

13.973 ~ 13.984 mm

0.5501 ~ 0.5506 in.

3A150

TD1300

Rockerarm I.D.

Factoryspec.

19.000 ~ 19.025 mm

0.74803 ~ 0.74902 in.

13.998 ~ 14.023 mm

0.5513 ~ 0.5529 in.

3A150

TD1300

704W285A

(G)Valve spring squareness (Tilt)

1. Place the spring on the surface plate and a squareat its side.

2. Measure the maximum distance A (See figure), ro-tating spring.

3. If the measurement exceeds the allowable limitreplace.

Valve springsquare ness

Allowablelimit

1.0 mm

0.039 in.

ENGINE SYSTEM

2-47D704-W00 Dec. 2004

704W287A

b. Timing gears and camshafts(A) Timing gear backlash

1. Set a dial indicator (lever type) with its tip on thegear tooth.

2. Move the gear to measure the backlash, holding itsmating gear.

3. If the backlash exceeds the allowable limit, checkthe oil clearance of the shafts and the gear.

4. If the oil clearance is improper, replace the gear.

Clearance Factoryspec.

Allowablelimit

0.04 ~ 0.11 mm

0.0016 ~ 0.0043 in.

0.15 mm

0.0059 in.

704W289A

704W288A

(B) Idle gear side clearance

1. Pull the idle gear collar 2 (1) and push the idle gear(2) to each end.

2. Measure the clearance A between the idle gear andthe idle gear collar 2 with a feeler gauge.

3. If the clearance exceeds the allowable limit, replacethe idle gear collar 1 (3).

Sideclearance

0.20 ~ 0.51 mm

0.0079 ~ 0.0201 in.

0.9 mm

0.035 in.

(1) Idle Gear Collar 2 (3) Idle Gear Collar 1

(2) Idle Gear

(C)Cam gear side clearance

1. Pull the cam gear (2) with the camshaft (1) to itsend.

2. Measure the clearance A between the cam gear (2)and the camshaft stopper (3).

3. If the clearance exceeds the allowable limit, replacethe camshaft stopper (3).

Sideclearance

Factoryspec.

Allowablelimit

0.07 ~ 0.22 mm

0.0028 ~ 0.0087 in.

0.3 mm

0.0118 in.

(1) Camshaft (3) Camshaft Stopper

(2) Cam Gear

Factoryspec.

Allowablelimit


2-48 D704-W00 Dec. 2004

704W291A

704W292A

(E) Idle gear oil clearance

1. Measure the idle gear shaft O.D. with an outsidemicrometer.

2. Measure the idle gear bushings I.D. with an insidemicrometer.

3. If the clearance exceeds the allowable limit, replacethe bushing.

(F) Replacing idle gear bushings

1. Press out the bushings using an idle gear bushingreplacing tool.

2. Clean the bushings and the bore, and apply oil tothem.

3. Press in the bushing using the replacing tool.

Oilclearance

Factoryspec.

0.025 ~ 0.066 mm

0.00098 ~ 0.00260 in.

0.02 ~ 0.054 mm

0.00078 ~ 0.00212 in.

3A150

TD1300


0.0039 in.ShaftO.D.

Factoryspec.

37.959 ~ 37.975 mm

1.49445 ~ 1.49508 in.

27.967 ~ 27.980 mm

1.10106 ~ 1.10157 in.

3A150

TD1300

BushingI.D.

Factoryspec.

38.000 ~ 38.025 mm

1.49606 ~ 1.49705 in.

28.0 ~ 28.021 mm

1.10236 ~ 1.10319 in.

3A150

TD1300

704W290A

(D) Injection pump gear side clearance

1. Pull the fuel camshaft and pull the injection pumpgear (1) to each end.

2. Measure the clearance A between the injection pumpgear (1) and the snap ring (2) on the fuel camshaft.

3. If the clearance exceeds the allowable limit, checkthe gear, the bearing and the key.

Sideclearance

Factoryspec.

Allowablelimit

0.15 ~ 0.57 mm

0.0059 ~ 0.0224 in.

0.9 mm

0.035 in.

(1) Injection Pump Gear (2) Snap Ring

A

ENGINE SYSTEM

2-49D704-W00 Dec. 2004

704W295A

704W294A

(H)Camshaft alignment

1. Support the camshaft with V blocks on the surfaceplate at both end journals and set a dial indicatorwith its tip on the intermediate journal.

2. Rotate the camshaft in the V block and get the ec-centricity (half of the measurement).

3. If the eccentricity exceeds the allowable limit, replacethe camshaft.

Eccentricity Allowablelimit

0.05 mm

0.002 in.

(I) Cam height

1. Measure the height of the camshaft lobes at theirlargest. O.D. with an outside micrometer.

2. If the measurement is less than the allowable limit,replace the camshaft.

704W293A

(G)Camshaft oil clearance

1. Measure the I.D. of the camshaft bore on the crank-case with an inside micrometer.

2. Measure the O.D. of the camshaft journal with anoutside micrometer.

3. If the clearance exceeds the allowable limit, replacethe shaft.

Oilclearance

JournalO.D.

BoreI.D.

Factoryspec.

Allowablelimit

Factoryspec.

Factoryspec.

0.050 ~ 0.091mm

0.00197 ~ 0.00358 in.

0.15 mm

0.0059 in.

39.934 ~ 39.950 mm

1.57221 ~ 1.57284 in.

40.000 ~ 40.025 mm

1.57480 ~ 1.57579 in.

Camheight

Specification 33.59 mm1.3224 in.33.54 mm1.3205 in.

3A150 (IN.)

Allowablelimit

Specification 33.69 mm1.3264 in.33.64 mm1.3244 in.

(EX.)

Allowablelimit

Specification 33.5 ~ 33.6 mm1.31889 ~ 1.32283 in.

33.45 mm1.3169 in.

TD1300 (IN.)

Allowablelimit

Specification 33.5 ~ 33.6 mm1.31889 ~ 1.32283 in.

33.45 mm1.3169 in.

(EX.)

Allowablelimit


2-50 D704-W00 Dec. 2004

11

10

9

704W297A

(B) Piston pin and brushing clearance

1. Measure the piston pin O.D. with an outside microme-ter.

2. Measure the piston pin busing I.D. with an insidemicrometer.

3. If the clearance exceeds the allowable limit with newbushing, replace the piston pin.

704W296A

c. Connecting rod and piston(A) Piston pin bore

1. Measure the I.D. of piston pin bore in piston (length-wise and widthwise of the piston) with a cylindergauge.

2. If the measurement exceeds the allowable limit, re-place the piston.

Piston Pinbore I.D.

3A150 25.000 ~ 25.006 mm

0.9843 ~ 0.9845 in.

25.03 mm

0.9854 in.

Factoryspec.

Allowablelimit

23.0 ~ 23.013 mm

0.9055 ~ 0.9060 in.

23.053 mm

0.9076 in.

Piston pinandbushingclearance

Factory spec. 0.014 ~ 0.038 mm

0.00055 ~ 0.00150 in.Allowable limit 0.15 mm

0.0059 in.Piston pinO.D.

Factoryspec.

25.002 ~ 25.011 mm

0.98433 ~ 0.98469 in.

23.002 ~ 23.011 mm

0.90559 ~ 0.90594 in.

3A150

TD1300

BushingI.D.

Factoryspec.

25.025 ~ 25.040 mm

0.98524 ~ 0.98583 in.

23.025 ~ 23.040 mm

0.90650 ~ 0.90709 in.

3A150

TD1300

704W298A

(C)Replacing piston pin bushing

1. Press out the bushing, using a piston pin bushingreplacing tool.

2. Clean the new bushing and the bore and apply oil tothem.

3. Press in the bushing, using the replacing tool.

IMPORTANT:• Align the oil holes of the connecting rod and the

bushing.

TD1300 Factoryspec.

Allowablelimit

ENGINE SYSTEM

2-51D704-W00 Dec. 2004

704W2A0A

(E) Piston ring clearance

1. Clean the ring and the ring grooves, and install eachring in its groove.

2. Measure the clearance between the ring and thegroove with a feeler gauge.

3. If the clearance exceeds the allowable limit, replacethe piston ring.

4. If the clearance still exceeds the allowable limit withthe new ring, replace the piston.

704W299A

(D)Piston ring end gap

1. Push down the ring into the cylinder to the lower limitof ring travel in the assembled engine with a piston.

2. Measure the ring gap with a feeler gauge.

3. If the gap exceed the allowable limit, replace the pis-ton ring.

Pistonringclear-ance

Factoryspec.

0.04 ~ 0.08 mm

0.00157 ~ 0.00315 in.

0.065 ~ 0.10 mm

0.00256 ~ 0.00394 in.

2ndring

3A150

TD1300


0.0059 in.

Pistonringendgap

Factoryspec.

0.55 ~ 0.70 mm

0.0217 ~ 0.0276 in.

0.25 ~ 0.40 mm

0.0098 ~ 0.05575 in.

2ndring

3A150

TD1300


0.0492 in.

Factory spec. 0.25 ~ 0.40 mm

0.0098 ~ 0.0157 in.

1.25 mm

0.0492 in.

Topring,

oil ringAllowable limit

Factoryspec.

0.02 ~ 0.06 mm

0.00079 ~ 0.00236 in.

0.02 ~ 0.06 mm

0.0008 ~ 0.00236 in.

Oilring

3A150

TD1300


0.0059 in.


2-52 D704-W00 Dec. 2004

704W2A2A

d. Crankshaft(A) Flywheel deflection and crankshaft end play

1. Set a dial indicator with its tip on the rear frictionface of the flywheel near the edge.

2. Turn the flywheel and measure the deflection or theuneven wear.

3. If the measurement exceeds the allowable limit, re-move the flywheel and check the mating faces ofthe crankshaft and flywheel.

4. If scored of worn excessively, regrind or replace theflywheel.

5. Move the crankshaft with flywheel back and forth toeach end and measure the end play.

6. If the play exceeds the allowable limit, replace theside bearing.

Deflection

End play

Allowablelimit

Factoryspec.

Allowablelimit

0.05 mm

0.0020 in.

0.15 ~ 0.31 mm

0.0059 ~ 0.0122 in.

0.5 mm

0.020 in.

(F) Connecting rod alignment

1. Remove the connecting rod bearing and install thebearing cap.

2. Install the piston pin in the connecting rod.

3. Install the connecting rod on the connecting rod align-ment tool.

4. Put a gauge over the piston pin and move it againstthe face plate.

5. If the gauge does not fit squarely against the faceplate, measure the space between the pin of thegauge and the face plate.

6. If the measurement exceeds the allowable limit, re-place the connecting rod. 704W2A1A

Space betweengauge pin andface plate

Allowablelimit

0.05 mm (0.0020 in.)

at 100 mm (3.94 in.)

of gauge pin span

ENGINE SYSTEM

2-53D704-W00 Dec. 2004

11

10

9

704W2A5A

704W2A4A

(C)Crankshaft journal and bearing 1 oil clearance

1. Measure the I.D. of the crankshaft bearing 1 with aninside micrometer.

2. Measure the O.D. of the crankshaft journal with anoutside micrometer.

3. If the clearance exceeds the allowable limit, replacethe bearing referring to Replacing Crankshaft Bear-ing 1.

(D)Replacing crankshaft bearing 1

1. Press out the crankshaft bearing 1 using replacingtool.

2. Clean a new crankshaft bearing 1 and bore, andapply engine oil to them.

3. Press fit a new bearing 1 using a inserting tool, tak-ing due care to see that the seam of bearing 1 facesthe exhaust manifold side.

Oilclearance

JournalO.D.

Bearing 1I.D.

Factoryspec.

Allowablelimit

Allowablelimit

Allowablelimit

0.040 ~ 0.118 mm

0.00157 ~ 0.00465 in.

0.20 mm

0.0079 in.

51.921 ~ 51.940 mm

2.04414 ~ 2.04488 in.

51.980 ~ 52.039 mm

2.04646 ~ 20.4878 in.

(1) Seam

704W2A3A

(B) Crankshaft alignment

1. Support the crankshaft with V blocks on the surfaceplate at its front and rear journals and set a dial indi-cator with its tip on the intermediate journal.

2. Rotate the crankshaft in the V blocks and get themisalignment (half of the measurement).

3. If the misalignment exceeds the allowable limit, re-place the crankshaft.

Misalignment Allowablelimit

0.08 mm

0.0031 in.


2-54 D704-W00 Dec. 2004

704W2A6A

(F) Crank pin and connecting rod bearing 2 oil clear-ance

1. Put a strip of Plastigage lengthwise in the center ofthe crank pin.

2. Install the connecting rod and tighten the screws tothe specified torque once, and remove the cap again.

3. Measure the amount of the flattening with the scaleand get the oil clearance.

4. If the clearance exceeds the allowable limit, replacethe bearing.

(E) Crankshaft journal and bearing 2 oil clearance

1. Put plasticgauge lengthwise in the center of thejournal.

2. Install the bearing cap and tighten the screw to thespecified torque once, and remove the cap again.

3. Measure the amount of the flattening with the scaleand get the oil clearance.

4. If the clearance exceeds the allowable limit, replacereplace the bearing.

Oilclearance

JournalO.D.

Bearing 2I.D.

Factoryspec.

Allowablelimit

Allowablelimit

Factoryspec

0.040 ~ 0.104 mm

0.00157 ~ 0.00409 in.

0.20 mm

0.0079 in.

51.921 ~ 51.940 mm

2.04414 ~ 2.04488 in.

51.980 ~ 52.025 mm

2.04646 ~ 2.04823 in.

Oilclearance

Factoryspec.

0.025 ~ 0.087 mm

0.00098 ~ 0.00343 in.

0.35 ~ 0.093 mm

0.0014 ~ 0.0037 in.

3A150

TD1300


0.0079 in.JournalO.D.

Factoryspec.

46.959 ~ 46.975 mm

1.84876~ 1.84947 in.

43.959 ~ 43.975 mm

1.73067 ~ 1.73130 in.

3A150

TD1300

Bushing 1I.D.

Factoryspec.

47.000 ~ 47.046 mm

1.85040 ~ 1.85221 in.

44.010 ~ 44.052 mm

1.73268 ~ 1.73433 in.

3A150

TD1300

704W2A7A

ENGINE SYSTEM

2-55D704-W00 Dec. 2004

704W2A8A

704W2A8A

e. Cylinder bore(A) Cylinder bore diameter

1. Measure the cylinder liner I.D. at sit positions shownin the figure to find the maximum wear.

3A150

TD1300

83.000 ~ 83.022 mm

3.2677 ~ 3.2690 in.

82.000 ~ 82.022 mm

3.2283 ~ 3.2292 in.

(A) Axial Direction

(B) Transverse Direction

1,2,3 Measuring Points


2-56 D704-W00 Dec. 2004

704W2B0A

A. CHECKINGa. Engine oil pressure1. Remove the oil pressure switch. Install the adapter

and pressure tester in its place.

2. Start the engine and run it until it is warmed up.Measure the oil pressure at both idling and ratedspeed.

3. If the oil pressure is less than the allowable limit,check the oil level, oil filter, oil pump relief valve, oilpassages and oil clearance.

Engine

oilpres-sure

Factory spec. more than 68.6 kPa

0.7 kgf/cm²

7.11 psi

At idlespeed

(Reference)

Tighteningtorque

Oilpressure

switch

14.7 ~ 19.6 N·m

1.5 ~ 2.0 kgf·m

10.8 ~ 14.5 lbf·ft

245 ~ 441 kPa

2.5 ~ 4.5 kgf/cm²

35.6 ~ 64.0 psi

294.2 kPa

3.0 kgf/cm²

42.7 psi

At ratedspeed

245 ~ 441 kPa

2.5 ~ 4.5 kgf/cm²

35.5 ~ 64.0 psi

294.2 kPa

3.0 kgf/cm²

42.7 psi

3A150

TD1300

Factoryspec.

Allowablelimit

Factoryspec.

Allowablelimit

7.4 LUBRICATING SYSTEM

ENGINE SYSTEM

2-57D704-W00 Dec. 2004

b. Oil filter1. Drain the engine oil and remove the oil filter to check it.

2. Check the relief valve for dirt, and the seat (2) andball (1) for damage.

3. If damaged, replace the filter.

4. Check the free length of spring (3).

5. If it is less than the allowable limit, replace it.

Spring freelength

Factoryspec

Allowablelimit

35 mm

1.38 in.

30 mm

1.18 in.

704W2B1A

(1) Relief Valve Ball (3) Relief Valve Spring

(2) Relief Valve Seat


2-58 D704-W00 Dec. 2004

704W2B4A

b. Rotor end clearance of oil pump1. Put a strip of plastigage on the rotor and assemble

the pump.

2. Disassemble the pump and measure the amount ofthe flattening with the scale to get the clearance.

3. If the clearance exceeds the allowable limit, replacethe pump.

Endclearance

Factoryspec.

Allowablelimit

0.105 ~ 0.150 mm

0.00413 ~ 0.00591 in.

0.20 mm

0.00781 in.

704W2B2A

704W2B3A

B. SERVICINGa. Rotor and lobe clearance of oil pump1. Measure the clearance between the outer and in-

ner rotor with a feeler gauge.

2. Measure the clearance between the outer and thehousing with a feeler gauge.

3. If the clearance exceeds the allowable limit, replacethe pump.

Outer andinner rotorclearance

Outer andinnerhousingclearance

Factoryspec.

Allowablelimit

Factoryspec.

Allowablelimit

0.10 ~ 0.16 mm

0.0039 ~ 0.0063 in.

0.20 mm

0.0079 in.

0.11 ~ 0.19 mm

0.0043 ~ 0.0075 in.

0.25 mm

0.0098 in.

ENGINE SYSTEM

2-59D704-W00 Dec. 2004

643W2D1A

704W2B5A

A. CHECKING ADJUSTINGa. Fan belt1. Measure the deflection, depressing the belt half-

way between the fan drive pulley and the alternatorpulley at 78 N (8 kgf, 18 lbs) of force.

2. If the deflection is not between the factory specifica-tions, loosen the bolts and nuts, and relocate thealternator to adjust.

3. If the belt is damaged or worn (See figure), replacethe belt.

Belttension(direction)

Factoryspec

7 ~ 9mm

0.28 ~ 0.35 in.

at 78 N (8 kgf, 18 lbs)

of force

b. Radiator water tightness1. Fill radiator with water to the specified amount and

warm up the engine.

2. Set a radiator tester and raise the water pressure tothe specified pressure.

3. Check the radiator for water leaks.

4. Pinhole water leaks may be repaired with radiatorcement. Larger leaks require radiator replacement.

Radiatorwatertightness

Factoryspec

No leaks at 137 kPa

(1.4 kgf/cm², 20 psi)

704W2B6A

7.5 COOLING SYSTEM

704W2B7A

c.Radiator cap tightness1. Attach a radiator tester on the radiator cap.

2. Apply 88 kPa (0.9 kgf/cm², 13 psi) of pressure andmeasure the pressure for 10 seconds.

3. If the pressure falls below 59 kPa (0.6 kgf/cm², 9 psi),replace the radiator cap.

Radiatorcaptightness

Factoryspec

More than 10 seconds

for pressure fall

from 88 ~ 59 kPa

(0.9 ~ 0.6 kgf/cm², 13 ~ 9 psi)


2-60 D704-W00 Dec. 2004

704W2C0A

c. Servicing(A) Thermostat valve opening temperature

1. Suspend the thermostat in the water by a string withits end inserted between the valve and seat.

2. Heating the water gradually, read the temperaturewhen the valve opens and then when the valveopens to approx. 8 mm (0.315 in.).

3. If the measurements are not within the factory speci-fications, replace the thermostat.

Openingtemperature

Factoryspec.

71 ± 1.5 °C

(160 ± 3 °F)

at beginning

Lower than 85 °C (185 °F)

At 8 mm (0.315 in.)

Of opening

704W2B8A

704W2B9A

B. DISASSEMBLING AND ASSEMBLINGa. Thermostat1. Remove the thermostat cover (2).

2. Take out the thermostat (1).

(When reassembling)

• Apply liquid gasket (Three Bond 1215 or equivalent)to the gasket.

b. Water pump1. Remove the fan and fan pulley.

2. Remove the water pump body from the gear casecover.

3. Remove the water pump flange (1).

4. Remove the impeller and water pump shaft (3).

5. Remove the impeller from the water pump shaft.

6. Remove the mechanical seal (4).

(When reassembling)

• Replace the mechanical seal (4) with new one.

(1) Thermostat (2) Thermostat Cover

(1) Water Pump Flange (4) Mechanical Seal

(2) Water Pump Bearing (5) Impeller

(3) Water Pump Body

ENGINE SYSTEM

2-61D704-W00 Dec. 2004

FuelInjectionpressure

Pressuredrop

Factoryspec.

Allowablelimit

14.71 MPa150 kgf/cm²

2134 psi

0.98 MPa10 kgf/cm²

142 psi

704W2C2A

704W2C1A

Injectiontiming

3A150 0.31 rad, 18° before T.D.C

A. CHECKING AND ADJUSTINGa. Injection pump(A) Injection timing

1. Remove the injection pipes.

2. Set the speed control lever to the maximum fueldischarge position.

3. Turn the flywheel counterclockwise (facing theflywheel) until the fuel flow through to the hole of thedelivery valve holder (1).

4. Continue to turn the flywheel until the fuel stopsflowing. Check the injection timing.

5. If the Fl mark does not align with the mark of thewindow on flywheel housing, add or remove theshim(s) (2) to adjust.

NOTE:• Apply liquid gasket (There Bond 1215 or equivalent)

to the shim, when reassembling.

(Reference)

• The t iming advances by removing 0.15 mm(0.006 in) of shim and retards by adding one, approx0.26 rad (1.5 °) of crank angle.

• Approx 3.6 mm (0.142 in.) of turn at the outer rim ofthe flywheel equals 0.26 rad (1.5 °) of crank angle.

(1) Delivery Valve Holder (2) Shim

(B) Delivery valve fuel tightness

1. Remove the injection pipes, glow plugs and the inletmanifold, and install the pressure tester.

2. With the speed control lever at the fuel injectionposition, turn the crankshaft counterclockwise (fac-ing the flywheel) until the pressure builds up to thefuel injection pressure.

3. Release the pressure in the delivery chamber bymoving down the plunger to bottom dead center (turnthe crankshaft c lockwise approx. 1.57 rad(90 °) from the FI timing).

4. If the pressure drop for 5 seconds exceeds the al-lowable limit, replace the delivery valve or pumpassembly.

5. If the pressure does not built up, replace the pumpelement with new one and test again.

TD1300 0.349 rad, 20° before T.D.C

7.6 FUEL SYSTEM


2-62 D704-W00 Dec. 2004

704W2C3A

(B) Fuel tightness of needle valve seat tightness

1. Connect the injection nozzle to the nozzle tester.

2. Apply a pressure 130 kgf/cm² (12.75 MPa, 1849 psi).Keep the nozzle under this pressure for 10 seconds.Check to see if fuel leaks from the nozzle.

3. If the fuel should leak, replace the nozzle.

b. Injection nozzle

Fuelinjectionpressure

Factoryspec.

14.71 MPa

150 kgf/cm²

2134 psi (1) Adjustment Washer

• Never contact with spraying diesel fuelunder pressure, pressure, which canhave sufficient force to penetrate theskin, causing serious personal injury.

• Be sure nobody is in direction of thespray.

CAUTION

(A) Fuel injection pressure

1. Set the injection nozzle to the nozzle tester.

2. Measure the injection pressure.

3. If the measurement is not within the factory specifi-cations, adjust with the adjustment washer (1) in-side the nozzle holder.

(Reference)

• Each adjustment washer of 0.1 mm (0.004 in.) willadjust the fuel injection pressure by approx. 10 kgf/cm².

704W2C4A

Documents

ck30 WM 02 engine01-28...0.039 in. Item Factory Specification Allowable Limit f. Rocker Arm 13.973 ~ 13.984 mm 0.55012 ~ 0.55055 in. 13.998 ~ 14.023 mm 0.55110 ~ 0.55209 in.--Item